NC0005321_Inspection_20010313

North Carolina
Department of Environment and Natural Resources
Division of Water Quality
Fayetteville Regional Office
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Kerr T. Stevens, Director
March 13, 2001
Mr. Brian Laney, Environmental Manager
Buckeye Lumberton, Inc.
1000 E. Noir.Street
Lumberton, NC 28359
SUBJECT: Compliance. Evaluation Inspection
Buckeye Lumberton Inc.
Wastewater Treatment Plant
NPDES Permit No. NC0005321
Robeson County
Dear Mr. Laney:
0TR/A 3// q01
ALIO/a& 7"
NCDENR
Enclosed is a copy of the Compliance. Evaluation Inspection conducted March 7, 2001:
As part of the inspection a tour of the Wastewater Treatment Plant was dconducted. All observations
and recommendations are in Part D. Summary of Findings/Comments of this! inspection report. The -
cooperation of Mr. Brian Laney and Mr. Ronald Radford (Grade IV ORC) was appreciated. The
objective we should all be striving for is NPDES permit compliance which in turn will provide
preservation of our receiving stream for generations to come. -
Please review the attached report. If you or your r staff have any questions
do not hesitate to contact me at 910-486-1541.
Sincerely,
Belinda S. Henson
Environmental Chemist
BSHlbsh
Enclosures
225 GREEN STREET - SUITE 714 / SYSTEL BUILDING / FAYETTEVILLE, NC 28301-5043
PHONE [phone] FAX [phone] WWW.ENR.STATE.NC.US/ENR/
AN EQUAL OPPORTUNITY / AFFIRMATIVE ACTION EMPLOYER- 50% RECYCLED/10% POST CONSUMER PAPER
DENR TOLL FREE HOTLINE: [phone]

NPDES COMPLIANCE INSPECTION REPORT
North Carolina Division of Water Quality
Fayetteville Regional Office,
Section A. National Data System Coding
Transaction Code: N NPDES NO. NC0005321 Date: 010307
Inspector: S Facility Type: 2'' •
Facility Evaluation Rating: 4 BI: N *QA: N
Section B: Facility Data
Name and Location of Facility Inspected:
Buckeye Lumberton Inc. WWTP
Entry Time: 9:50am
Exit Time/Date: 2:00pm/010307
Name(s), Title(s) of On -Site Representative(s):
Brian Laney - "Environmental Manager"
Ronald Radford (Certified Grade IV Operator) - "ORC"
Phone Number(s): [phone]
Name, Title and Address of Responsible Official
Mr. Brian Laney, Environmental Managei'
Buckeye Lumberton, Inc.
1000 E. Noir Street
Lumberton, NC 28359
Section C: Areas Evaluated During Inspection
Inspection Type: C
Reserved:
Reserved:
Permit Effective Date: 000301
Permit Expiration Date: 010731
Contacted: no
(S Satisfactory, M = Marginal, U:= Unsatisfactory, N = Not Evaluated, N/A = Not Applicable)
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Laney
Page 3
March 13, 2001
Section D: Summary of Findings/Comments:
1. The shortage of cotton fiber has decreased operation of manufacturing of their products from seven to
five days at this facility. The small fibers surrounding the cottonseed is what is used to produce the
paper products at this facility. An overall decrease in the number of oil! mills that process cottonseed for
oil has affected the market conditions.
2. The facility has submitted a request for a permit modification to increase the hydraulic design capacity
from 1.8 MGD to 2.5 MGD. All other permit conditions will remain the same. This application is
currently in the NPDES permitting unit for final review.
3. The domestic wastewater from this facility is discharged to the City of Lumberton's wastewater
treatment plant.
Carbon dioxide is added to the influent to neutralize pH when necessary.
5. Three main pumps and one smaller one is in place to pump the influent into the plant. One pump is used
at any given time with the other pumps used as backups. One pump was not operational at the time of
the inspection. An alarm system is in place which allows detection of a high flow through a float system.
6. The primary clarifier appeared to be operational with some foam (not excessive) on the water surface.
7. The aerobic selector is made up of: influent, return activated sludge (RAS), and solids from the
secondary clarifiers. The selector was installed to assist with filamentous bacteria reduction.
8. The aeration basin has a capacity of 5.5 MG. Eighteen (18) aerators are located in the basin with six
(6) at the head of the basin which are 75 Horsepower and the remaining being 40 Horsepower.
Ammonia and Phosphoric Acid is added to the aeration basin at a rate of 20 gallons/day to assist with
treatment of the wastewater. The aeration basin appeared to be operating adequately. The most recent
Mixed Liquor Suspended Solids (MLSS) result was 6300 mg/L: Theioptimum range for this facility is
5500 - 6000 mg/L as per Mr. Laney. Defoamer is added to the MLSS to assist with foam reduction.
9. Clarifier #1 had a sludge depth of 13 feet with a tank depth of 15 feet. Clarifier #2 had a sludge depth
of 13 '/2 feet with a tank depth of 15 feet. Clarifier #3 had a sludge depth of 4 '/2 feet with a tank depth
of 10 feet. At the time of the inspection 222 gallons/minute of solids were being wasted. An extensive
solids disposal system is present with the following components: filter press, concrete storage
facility at farm site and adequate amount of land to apply it to. Please explain why the solids
disposal system used has not decreased the sludge blankets in clarifiers #1 and #2. The facility
has inadequate water pressure to clean the launders and weirs of secondary clarifiers #1 and #2.
Please respond to these comments by April 20. 2001.

Laney
Page 4
March 13, 2001
10. The two return pumps located adjacent Clarifier #1 and #2 were leaking oil. There is containment
around this area with a drain which flows to the head of plant. The pumps should be repaired
immediately to eliminate oil leakage. Please respond to this by April 20.2001.
11. The effluent appeared to be free of solids with a brown color which is representative of this specific type
of wastewater.
12. The effluent composite sampler 3710 Isco is flow proportional by variable volume/constant time. The
temperature of the effluent composite sampler refrigerator was 4 degrees Celsius. The proper
preservation for sample storage is 0 - 4 degrees Celsius. The tubing of the effluent sampler appeared
to have some solids in it. A recommendation is to clean or replace the tubing as soon as possible
to eliminate possible NPDES permit limit violations.
13. The effluent outfall was easily accessible. The effluent discharges directly, into the Lumber River.
14. The effluent Model 2100 Ultrasonic flowmeter is used to report flow on the Discharge Monitoring
Reports (DMRs). The flow meter was calibrated November 28, 2000 by instrumentation staff of the
facility. It is advisable that the flow meter calibration document contain the % error before and after
calibration in the future by instrumentation staff
15. The solids wasted from the system are from the primary and secondary clarifier. The biosolids are
dewatered by polymer and a sludge press. The solids go into the belt press at 1 - 1 'h percent and leave
the press at 15 - 18 percent. All biosolids are land applied to permitted land. The land application
permit # WQ0002932 permits approximately 1684 acres.
16. The facility has a certified laboratory on site that analyzes the following NPDES permit required
parameters: pH, Temperature, Dissolved Oxygen, Fecal Coliform, Ammonia, BOD, Total Suspended
Solids, Chlorine Residual and Conductivity. All other required parameters are contracted with the
commercial laboratory "TBL".
17. Laboratory records were reviewed for the months July through September 2000 and compared to
Discharge Monitoring Records (DMRs). All records reviewed appeared to be adequately reported.
18. A compliance evaluation analysis report for the period January through December 2000 did not reveal
any monthly violations.
19. As a reminder as per our Administrative Code Section: 15A NCACI 2B .0506(b)(3)(F)(i)-the date on
which collection of composite samples is commenced or data shall be entered onto the monitoring report
form on the date that has the greater number of hours in it. The following examples will assist you in
understanding the reporting date:
A. If the composite sample is started on Tuesday, March 6, 2001 at 9:OOAM and the sample is
withdrawn from the composite sampler Wednesday March'7, 2001 at 9:OOAM; the day with
the greater number of hours in it is Tuesday, March 6, 2001.

Laney
Page 5
March 13, 2001
B. If the composite sample is started on Tuesday, March 6, 2001 at 6:OOPM and the sample is
withdrawn from the composite sampler on Wednesday, March 7, 2001 at 6:OOPM; the day with
the greater number of hours in it is Wednesday, March 7, 2001.
20. The "Backup Operator" for this facility. is Kenny Emanuel. He is' a Grade III certified wastewater
operator.
Name and Signature of. Inspector Agency/Office/Telephone Date
Belinda S. Henson f 14:"° 4 DENR/Fayetteville/[phone] ` 13- 6
Name and Signature of Reviewer Agency/Office/Telephone Date
Grady Dobson ( DENR/Fayetteville/[phone]/ `I��/
Action Taken
Regulatory Office Use Only
Compliance Status
Noncompliance
Compliance
Date

Section D: Summary of Findings/Comments
Brief Facility Description:
A 1.8 MGD WWTP consisting of screening. grit removal, primary clarification, equalization.
equalization basin, aerobic selector, aeration basin with nutrient addition and methanol feed, final
clarification, sludge holding tank. and sludge press.
FACILITY SITE REVIEW
No . N/A 1. Treatment units properly operated and maintained'.
Yes NSo N/A 2. Standby power or other equivalent provision provided.
Yes No N/A 3. Adequate alarm system for power or equipment failure available.
No N/A
No N/A
4. Sludge disposal procedures appropriate:
a. Disposal of sludge according to regulations
b. State approval for sludge disposal received.
No N/A 5. All treatment units other than backup units in service.
No N/A 6. Sufficient sludge disposed of to maintain treatment process equilibrium.
No N/A 7. Adequate number of qualified operators on staff.
Yes No N/A 8. Established procedures available for training'new employees.
Yes No- N/A 9. Adequate spare parts and supplies inventory
maintained.
Yes N/A 10. a. Hydraulic overflows and/or organic overloads experienced
Yes N/A - b. Untreated bypass discharge occurs during power failure
Yes N" N/A c. Untreated overflows occurred since last inspection.
Yes No N/A 11. Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
Yes) No N/A 12. Plant is generally clean, free from open trash areas.

Yes No
Yes No
Yes No
Yes No
13. Screening:
a. Manual
b. Mechanical
c. Buildup of debris
d. Screenings properly disposed of.
14. Grit Removal:
Yes No ICIPA a. Excessive organic content in the grit chamber
Yes No N/A b. Excessive odors.
Yes No / c. Grit properly disposed of.
Yes
Yes
Yes
Yes
0
�.
1t.
N/A
N/A
N/A
N/A
e )No N/A
Yes o, N/A
Yes o N/A
Yes N/A
Yes N/A
Yes n N/A
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
N/A
N/A
N/A
N/A
Page 2
15. Primary clarifier:
a. Excessive gas bubbles
b. Black and odorous wastewater
c. Poor suspended solids removed
d. Excessive buildup of solids in center well ;of circular clarifier
e. Weirs level
f. Weir blockage
g. Evidence of short circuiting
h. Lack of adequate scum removal
i. Excessive floating sludge
j. Broken sludge scraper.
16. Trickling Filter:
a. Trickling filter ponding(indicating clogged media)
b. Leak at center column of trickling filter's distribution arms
c. Uneven distribution of flow on trickling filter surface
d. Uneven or discolored growth
e. Excessive sloughing of growth
f. Odor
g. Clogging of trickling filter's distribution'arm orifices
h. Filter flies, worms, or snails.
17. Rotating Biological Contactors (RBC):
a.. Development of white biomass onrotating biological contactor
media
b. Excessive sloughing of growth
c. Excessive breakage of rotating disks or shafts, in RBC units
d. Excessive breakage of paddles on brush aerators
e. Shaft, bearing, drive gear, or motor failure on disk or brush aerators.

18. Activated Sludge Basins/Oxidation Ditches:
Yes 6 N/A a. Dead spots
Yes Q N/A b. Failure of surface aerators
Yes 3 N/A . c. Air rising in clumps
Yes N" N/A d. Dark foam or bad color
Yes N/A e. Thick billows of white, sudsy foam
Yes No/ f. Air rising unevenly
Yes No Mk g. Excessive air leaks in compressed air piping.
Yes No
Yes No
Yes No
Yes No
/A
N/A
N/A
N/A;
Page 3
19. Stabilization Ponds/Lagoons:
a. Excessive weeds including duckweed in 'stabilization ponds
b. Dead fish or aquatic organisms
c. Buildup of solids around influent pipe
d. Excessive scum on surface.
20. Secondary Clarifier:
Yes N/A a. Excessive gas bubbles on surface
Yes La? N/A b. Unlevel overflow weirs
Yes CN�"b N/A c. Weir blockage
Yes I o N/A d. Evidence of short circuiting
Yes &No N/A e. Excessive buildup of solids in center well of circular clarifier
Yes N/A f. Pin floc in overflow
Yes N/A g. Ineffective scum rake
Yes N/A h. Floating sludge on surface
Yes No N/A i. Excessive high sludge blanket So r' e w t'`I t
Yes N/A j. Clogged sludge withdrawal ports on secondary clarifier.
Yes No
Yes No
Yes No
Yes . No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
N/A
N/A
N/A
N/
N/;
"N/
N/
N/A
N/A
N/A
N/A
N/A
N/A
21. Filtration:
a. Filter surface clogging
b. Short filter run
c. Gravel displacement of filter media
d. Loss of filter media during backwashing
e. Recycled filter backwash water in excesslof 5 percent
f. Formation of mudballs in filter media.
22. Chlorination Unit:
a. Sludge buildup in contact chamber
b. Gas bubbles
c. Floating scum and/or solids
d. Adequate ventilation of chlorine feeding, room and storage area
e. NIOSH-approved 30 minute air pack
f. All standing chlorine cylinders chained in place
g. All personnel trained in the use of chlorine
h. Proper chlorine feed, storage, and reserve supply.

Yes No
Yes . No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No eA 23. .Ultraviolet radiation disinfection present and, in use.
24. Dechlorination:
a. Proper storage of sulfur dioxide cylinders
b. Adequate ventilation of sulfur dioxide feeding room
c. Automatic sulfur dioxide feed or feedback control not operating
properly.
1
TT/A
N/A
N/A
N/A
Page 4
25. Aerobic Digester:
a. Excessive foaming in tank
b. Noxious odor
c. Mechanical aeration failure
d. Clogging of diffusers..
26. Anaerobic Digester:
a.. Floating cover tilting
b. Gas burner operative
c. Supernatant has a sour odor.
27. Sludge Drying and/or disposal:
Yes No Cati a. Poor sludge distribution ondrying beds
Yes No N b. Vegetation in drying beds
Yes No 1[L c: Dry sludge remaining in drying beds
Yes No /A d. Dry sludge stored on site
Yes No N/ e. Filtrate from sludge drying beds returned 'Ito front of plant
£ Approved disposal site for the sludge
g. Sludge land applied.
Ye ' No
Ye - No
N/A
N/A
28. Filter Press:
Yes gg ° N/A a. High level of solids in filtrate from filter presses or vacuum filters
Yes o` N/A b. Thin filter cake caused by poor dewaterii g
Yes N/A c. Sludge buildup on belts and/or rollers of filter press
Yes Igo"; N/A d. Excessive moisture in belt filter press sludge cake..
Yes No
Yes No
Yes No
29. Polishing Ponds or Tanks:
a. Objectionable odor, excessive foam, floating solids, or oil sheens on
water surface
b. Solids or scum accumulations in tank or a't side of pond
c. Evidence of bypassed polishing ponds or tanks because of low
capacity.

Y
Page 5
30. Plant Effluent:
ONo N/A a. Excessive suspended solids, turbidity, foam, grease, scum, color, and
other macroscopic particulate matter present
es No N/A b. Potential toxicity (dead fish, dead plant at discharge)
No N/A c. Outfall discharge line easily accessible.
Ye� No
No
cleNo
Yes
. Yes
Yes
Yes
Yes
No
No
No
No
No
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Yes No N/A
Ws) No N/A
(Yes No N/A
Ye No N/A
Yes ) No N/A
31. Flow Measurement:
a. Proper placement of flow measurement device
b. Flow meter calibrated
c. Buildup of solids in flume or weir
d. Broken or cracked flume or weir
e.. Properly functioning magnetic flowmeter!
f. Clogged or broken stilling wells
g. Weir plate edge corroded or damaged
h. System capable of measuring maximum flow
i. Flow measurement error less than 10%.
32. Sampling:
a. Sampling and analysis completed on parameter's specified by permit
b. Samples refrigerated during compositing
c. Composite sample temperatures maintained at 0 to 4 degrees Celsius
during sampling
d. Contract laboratory used for sample analysis
e.. Composite samples obtained are flow proportional.
RECORDKIEEPING AND REPORTING
Yes No N/A 1. Records and reports maintained as required by permit.
Yes No N/A 2. All required information available, complete, and current.
YeJ No N/A • 3. Records maintained for 3 years and all sludge records maintained for 5
years.
(Yes) No N/A 4. Analytical results consistent with data reported on 'DMRs.
5. Sampling and analyses data adequate and include:
No N/A a. Dates, times, and location of sampling
es/ No N/A b. Name of individual performing sampling
No N/A .c. Results of analyses and calibration
No N/A d. Dates of analyses
es/ No N/A e. Name of person performing analyses.

Page 6
6. Monitoring records adequate and include:
Yes-.' No . N/A a. Monitoring charts kept for 3 years
(TO, No N/A b. Flowmeter calibration records kept for 3 years.
Yes No N/A 7. Laboratory equipment calibration and maintenance records adequate.
No N/A
Yes No
8. BOD incubator temperature maintained at 20 +/- 1 Degrees Celsius
and the temperature maintained in a log ;forevery day of operation.
9. Fecal coliform incubator maintained at 44.5 +/- 0.2 Degrees
Celsius and the temperature maintained in a log for every day of
operation. .
10. Plant records adequate and include:
No N/A a. 0 & M Manual
Yes No N/A _ b. "As -built" engineering drawings
Yes No N/A c. Schedules and dates of equipment maintenance repairs
Yes No N/A d. Equipment data cards.
Yes No /A) 11. Permittee is meeting compliance schedule)
es No N/A 12. DMRs complete and include all NPDES permit required parameters.
Yes No N/A 13. ORC visitation logs available and current.
Ye No N/A 14. ORC certified at a level equal to or greaten than the classification of
the wastewater facility.
Yes No N/A 15. Backup Operator certified at one level less than the classification of
the wastewater facility or greater.=
No N/A 16. Current copy of the complete NPDES permit on site.
Yes) No N/A 17. Facility description verified as contained in NPDES permit.
Revised 7/11/00
by Belinda Henson

INSPECTION REPORT
UPDATE OPTION: TRX: 5IF .KEY: NC0005321INSCEI1 010307
SYSMSG: *** DATA ADDED SUCCESSFULLY ***
PERMIT--- NC0005321 REG/COUNTY 06 ROBESON
FACILITY-- BUCKEYE LUMBERTON, INC. LOC-- LUMBERTON
INS TYPE
CEI
NEXT PLANNED
INSPECTION INSPECTED BY:
DATE: 010307 HSB
REPORT INSPECTION DMR . RESPONSE RECEIVED
-DATE STATUS STATUS DUE DATE DATE 1
0.1.03.13 C C 1
COMMENTS:-

BUCKEYE
1000 EAST NOIR ST., P.O. BOX 1305
LUMBERTON, NORTH CAROLINA 28359
TEL [phone] FAX [phone]
Belinda Henson
North Carolina Division of Water Quality
Fayetteville Regional Office
Subject: NPDES Compliance Inspection Report
CC: Grady Dobson
Belinda:
DEAR -FRO
APR 202001
DO
This letter will serve as a response to the NPDES Compliance Inspection Report
for the inspection of the Buckeye Lumberton Incorporated wastewater treatment plant
performed March 7, 2001.
Your first comment was regarding the sludgeblankets in the #1 and #2 secondary
clarifiers. At the time of the inspection, both the #1 and #2 secondary clarifiers had,
relatively high sludge blankets. The -#1.secondary clarifier had a sludge depth of.13, feet
with a tank depth of 15 feet. The #2 secondary clarifier had a sludge depth of 13.5 feet
with a tank depth of 15 feet. The #3 secondary. clarifier had a sludge depth of 4.5 feet
with a tank depth of 10 feet. We- were .wasting 222 gallons/minute of solids at the time of
the inspection.
There are a few things that contributed to the higher than normal sludge blankets
on the day of the inspection. The plant had been shut down over the period of March 2-4
(Due to some market conditions, we are currentlyrunning for eleven days, and taking
three days down). This modified running schedule hinders the efficiency of the
wastewater treatment plant. We usually do not waste while the plant is shut down,
because of the drastic effect on solids/biomass in the system. After coming back up to
full production, it sometimes takes one or two days to get our system back to equilibrium.
On startup days we generally. see higher loads to the treatment. plant. This coupled with
the fact that we also see our settlability deteriorate somewhat during shutdown, creates
some bulking of the sludge blankets as we startup.
At the time of the inspection, we were also beginning the process of switching
from winter to summer operation. We normally operate ata MLSS of 6000 mg/L in the
aeration basin over the winter, and around 4500 mg/L in the summer. We were wasting
at a rate of 0.1-MGD at the time of the inspection to keep a MCRT of 26. For summer
operation, we intend to operate at a MCRT of around 15, and will be wasting at a rate of
BUCKEYE LUMBERTON INC.

BUCKEYE
1000 EAST NOIR ST., P.O. BOX 1305
LUMBERTON, NORTH CAROLINA 28359
TEL [phone] FAX [phone]
approximately 0.2-MGD. This will lower the overall solids in the system, and we should
not see the sludge blankets get as high during this period.
Since the time of the inspection, we have been able to keep the sludge blankets at
an average depth of five (5) to seven (7) feet. We have been wasting extra solids on the
day before and after a shutdown to reduce the total solids in the system, and deter high
sludge blankets on startup days. We continuously check the sludge blankets to monitor
the levels in each of the clarifiers, and keep them at normal levels: We will continue to
pay special attention to these blanket depths. I am also having weekly conference calls
with our wastewater consultant from Black & Veatch to discuss any such issues that
arise.
In response to your comments about not having enough water pressure to clean
the weirs of the #1 and #2 secondary clarifiers, we initiated a project to install a water
booster pump at this location, as well as at the North. end of the aeration basin to service
the primary clarifier as well as the #3 secondary. Ronald Radford, (ORC), Tommy
Hammonds (Maintenance), and myself are evaluating this project J We are in the process
of receiving quotes from some pump manufacturers on this application. I will notify you
when this system is in place.
At the time of the inspection, the two return pumps (Fairbanks Morris pumps)
located adjacent to the #1 secondary clarifier were leaking. These; pumps are used to
pump effluent from the aeration basin to the #3 secondary clarifier located at the North
end of the basin. The problem with the seal on these pumps is that we have no water at
this location to use as seal water. The pump is actually using the effluent as seal water. I
am working with Jeff Hester (Maintenance Planner) to evaluate another type of
"waterless" seal for this application. While we are evaluating other options, there has
been a work order submitted to replace the seals in both pumps until a better solution is
reached. Because staffmg in the maintenance department is at an all time low, and the
fact that there is containment around these pumps, this was assigned a #2 priority (#1
being the highest priority, and #5 being the lowest). I will follow-up with you by e-mail
once this has been completed.
There was also a recommendation to change the tubing on our effluent composite
sampler. Since the time of the inspection, we have replaced the old tubing and have put
extra tubing in stock for replacement as needed.
BUCKEYE LUMBERTON INC.

BUCKEYE
1000 EAST NOIR ST., P.O. BOX 1305
LUMBERTON, NORTH CAROLINA 28359
TEL [phone] FAX [phone]
If you have any questions, comments, or would like any additional information, please
give me a call at (910) 737 — 3243.
Thanks,
Sivriv. eavvteA3
Bryan A. Laney
Environmental Manager
BUCKEYE LUMBERTON INC.